Multiphysics Analysis of Automotive Components for Product Portfolio Optimization

In this study, the pillars A, B and C from the Body-in-White (BIW) of a pickup passenger vehicle were considered, and the steels used for these components were identified based on the A2MAC1 platform, the SAEJ2947 standard, and state-of-the-art literature. Subsequently, these steels were compared with the client's product portfolio to propose a steel that meets the characteristics demanded by the automotive market for each of the components considered in the BIW. Next, the performance of each of the three pillars with these steels was validated and compared through crashworthiness simulations using Finite Element Analysis (FEA) with ANSYS LS-DYNA software. These simulations modeled the behavior of the pillars on side impact tests, with meshed parts based on the 2014 Chevrolet Silverado 1500 FEA model from the CCSA of the George Mason University. The impact speed was based on the Oblique pole side impact testing protocol from Euro NCAP; the time simulation was based on the Side impact Crashworthiness Evaluation 2.0 Rating Guidelines from the IIHS. To compare materials’ behavior, different curves were defined for each case. The tested materials were evaluated by comparing internal energy and displacement on each of the three pillars. Finally, results regarding the behavior of the different materials were discussed.